Double-metal cyanide catalysts which can be used to prepare polyols and the processes related thereto

ABSTRACT

The present invention is directed to double metal cyanide catalysts (“DMC”) which can be used to prepare polyols. DMC catalysts of the present invention are prepared by combining i) at least one metal salt; ii) at least one metal cyanide salt; iii) at least one organic complexing ligand; iv) at least one alkaline metal salt; and, optionally, v) at least one functionalized polymer. The present invention is also directed to a process for preparing a polyol in the presence of a DMC catalyst prepared according to the process of the present invention. 
     Surprisingly, DMC catalysts of the present invention, which are preferably prepared with at least one alkaline metal halide, have acceptable activity and can be used to catalyze oxyalkylation reactions. Additionally, DMC catalysts produced by the process of the present invention can be used to prepare polyols which have reduced levels of high weight tail.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed to double-metal cyanide (“DMC”)catalysts which can be used to prepare polyols. The present invention isalso directed to a process for preparing DMC catalysts. The presentinvention is further directed to a process for polymerizing an alkyleneoxide in the presence of a DMC catalyst prepared according to theprocess of the present invention.

BACKGROUND OF THE INVENTION

In the preparation of polyoxyalkylene polyols, starter compounds havingactive hydrogen atoms are oxyalkylated with alkylene oxides in thepresence of a suitable catalyst. For many years, basic as well as DMCcatalysts have been used in oxyalkylation reactions to preparepolyoxyalkylene polyols. Base-catalyzed oxyalkylation involvesoxyalkylating a low molecular weight starter compound (such as propyleneglycol or glycerine) with an alkylene oxide (such as ethylene oxide orpropylene oxide) in the presence of a basic catalyst (such as potassiumhydroxide (KOH)) to form a polyoxyalkylene polyol.

In base-catalyzed oxyalkylation reactions, propylene oxide and certainother alkylene oxides are subject to a competing internal rearrangementwhich generates unsaturated alcohols. For example, when KOH is used tocatalyze an oxyalkylation reaction using propylene oxide, the resultingproduct will contain allyl alcohol-initiated, monofunctional impurities.As the molecular weight of the polyol increases, the isomerizationreaction becomes more prevalent. As a result, 800 or higher equivalentweight poly(propylene oxide) products prepared using KOH tend to havesignificant quantities of monofunctional impurities. Monofunctionalimpurities tend to reduce the average functionality and broaden themolecular weight distribution of the polyol.

Unlike basic catalysts, DMC catalysts do not significantly promote theisomerization of propylene oxide. As a result, DMC catalysts can be usedto prepare polyols which have low unsaturation values and relativelyhigh molecular weights. DMC catalysts can be used to produce polyether,polyester and polyetherester polyols which are useful in applicationssuch as polyurethane coatings, elastomers, sealants, foams andadhesives.

DMC-catalyzed oxyalkylation reactions, however, are known to producesmall amounts of high molecular weight polyol impurities (typically,molecular weights in excess of 100,000 Da). These high molecular weightimpurities are often referred to as the “high molecular weight tail”. Inelastomers and other systems, the high molecular weight tail mayinterfere with hard segment phase out as well as with the alignment ofhard segments responsible for strength and modulus properties. Inpolyurethane foam systems, for example, polyols which have a highmolecular weight tail produce course foam cells, very tight foams orweak foams or contribute to foam collapse.

DMC catalysts are known and are described in,;for example, U.S. Pat.Nos. 3,278,457, 3,278,459, 3,289,505, 3,427,256, 4,477,589, 5,158,922,5,470,813, 5,482,908, 5,545,601, 5,627,122 and 6,423,662 as well as inWO 01/04180 and WO 02/09875. DMC catalysts are typically prepared bymixing an aqueous solution of a metal salt with an aqueous solution of ametal cyanide salt in the presence of an organic complexing ligand. Aprecipitate forms when these two solutions are mixed together. Theresulting precipitate is isolated and then washed.

The art teaches that, during the preparation of a DMC catalyst, alkalinemetal salts are incorporated into the catalyst. See Huang et al.,“Controlled Ring-Opening Polymerization of Propylene Oxide Catalyzed byDouble Metal-Cyanide Complex,”, Journal of Polymer Science, Vol.40, page1144 (2002); U.S. Pat. No. 3,278,457, column 5, lines 40-44; and WO02/09875, page 5, lines 5-12. The art also teaches that these occludedions must be removed during the preparation of a DMC catalyst. See Huanget al., page 1144; U.S. Pat. No. 3,278,457, column 5, lines 57-58; andWO 02109875, page 5, lines 5-12. U.S. Pat. No. 6,423,662 (at column 6,lines 47-50), WO/01/04180 (at page 8, lines 17-19), and U.S. Pat. No.3,278,457 (at column 5, lines 45-58), for example, teach those skilledin the art to wash the precipitate formed during the preparation of aDMC catalyst as thoroughly as possible in order to remove essentiallyall of these occluded ions.

SUMMARY OF THE INVENTION

The present invention is directed to process for preparing a DMCcatalyst which involves combining: i) at least one metal salt; ii) atleast one metal cyanide salt; iii) at least one organic complexingligand; iv) at least one alkaline metal salt; and, optionally, v) atleast one functionalized polymer.

The present invention is also directed to a process for preparing apolyol in the presence of a DMC catalyst prepared according to theprocess of the present invention.

The present invention is also directed to a DMC catalyst which isrepresented by the following general formula (I)

M¹ _(x)([M² _(x′)(CN)_(y)]_(z).[M³ _((-x-)(A)) _((-y-)]).L)¹.L².M⁴(B)_(z)  (I)

Surprisingly, DMC catalysts of and produced by the process of thepresent invention, which are preferably prepared with at least onealkaline metal halide, have acceptable activity and can be used tocatalyze oxyalkylation reactions.

Additionally, DMC catalysts produced by the process of the presentinvention can be used to produce polyols which have reduced levels ofhigh molecular weight tail.

DESCRIPTION OF THE INVENTION

In a first aspect, the present invention is a process for preparing aDMC catalyst comprising combining: i) at least one metal salt; ii) atleast one metal cyanide salt; iii) at least one organic complexingligand; iv) at least one alkaline metal salt; and, optionally, v) atleast one functionalized polymer, under conditions sufficient to form acatalyst.

In a second aspect, the present invention is a process for preparing apolyol comprising reacting i) at least one starter compound havingactive hydrogen atoms with ii) at least one oxide in the presence ofiii) at least one DMC catalyst which is prepared according to theprocess of the present invention, under conditions sufficient to form apolyol.

In another aspect, the present invention is a DMC catalyst which isrepresented by the formula M¹ _(x)([M² _(x′)(CN)_(y)]_(z).[M³_((-x-))(A)_((-y-))]).L¹.L².M⁴(B)_(z),

wherein

M¹ represents at least one metal;

[M² _(x′)(CN)_(y)] represents at least one metal cyanide;

[M³ _(x)(A)_(y)] represents at least one transition metal salt;

M⁴(B)_(z) represents at least one alkali metal salt;

L¹ represents at least one organic complexing ligand;

L² is optional and can represent at least one functionalized polymer;and

x, x′, y and z are integers and are chosen such that electroneutralityof the DMC catalyst exists.

In yet another aspect, the present invention is a process for preparinga polyol comprising reacting i) at least one starter compound havingactive hydrogen atoms with ii) at least one oxide in the presence ofiii) at least one DMC catalyst which is represented by the formula M¹_(x)([M² _(x′)(CN)_(y)]_(z).[M³ _((-x-))(A)_((-y-))]. L¹.L². M⁴(B)_(z).

wherein

M¹ represents at least one metal;

M² _(x′)(CN)_(y) represents at least one metal cyanide;

[M³ _(x)(A)_(y)]. represents at least one transition metal salt;

M⁴(B)_(z) represents at least one alkaline metal salt;

L¹ represents at least one organic complexing ligand;

L² is optional and can represent at least one functionalized polymer;and

x, x′, y and z are integers and are chosen such that electroneutralityof the DMC catalyst exists.

Any metal salt can be used in the present invention. Preferably, watersoluble metal salts which are known in the art are used in the presentinvention. Examples of metal salts which are useful in the presentinvention include, for example, zinc chloride, zinc bromide, zincacetate, zinc cetylacetonate, zinc benzoate, zinc nitrate, zincpropionate, zinc formate, iron(II) sulfate, iron(II) bromide, cobalt(II)chloride, cobalt(II) thiocyanate, nickel(II) formate, nickel(II) nitrateand mixtures thereof.

Any metal cyanide salt can be used in the present invention. Examples ofmetal cyanide salts which can be used in the present invention include,for example, cyanometalic acids and water-soluble metal cyanide salts.Preferably, water soluble metal cyanide salts which are known in the artare used in the present invention. Metal cyanide salts which are usefulin the invention include, for example,potassium hexacyanocobaltate(III),potassium hexacyanoferrate(II), potassium hexacyanoferrate(II), lithiumhexacyanoiridate(III), lithium hexacyanocobaltate(III), sodiumhexacyanocobaltate(III) and cesium hexacyanocobaltate(III) are used inthe present invention.

Metal salts of the present invention are preferably combined with metalcyanide salts of the present invention to form DMC compounds. DMCcompounds which are useful in the present invention include, forexample, zinc hexacyanocobaltate(III), zinc hexacyanoiridate(III), zinchexacyanoferrate(II), zinc hexacyanoferrate(III), zinchexacyanocolbaltic acid, cobalt(II) hexacyanocobaltate(III) andnickel(II) hexacyanoferrate(II). Zinc hexacyanocobaltate is particularlypreferred.

Any organic complexing ligand can be used in the present invention.Organic complexing ligands useful in the present invention are known andare described in, for example, U.S. Pat. Nos. 3,404,109, 3,829,505,3,941,849, 5,158,922 and 5,470,813, as well as in EP 700 949, EP 761708, EP 743 093, WO 97/40086 and JP 4145123. Organic complexing ligandsuseful in the present invention include, for example, water-solubleorganic compounds with heteroatoms, such as oxygen, nitrogen, phosphorusor sulfur, which can form complexes with the DMC compound.

Suitable organic complexing ligands useful in the present inventioninclude, for example, alcohols, aldehydes, ketones, ethers, esters,amides, ureas, nitriles, sulfides and mixtures thereof. Preferredorganic complexing ligands useful in the present invention includewater-soluble aliphatic alcohols, such as, for example, ethanol,isopropanol, n-butanol, iso-butanol, sec-butanol and tert-butanol.Tert-butanol is particularly preferred.

Any alkaline metal salt can be used in the present invention.Preferably, alkali metal halides are used in the present invention. Morepreferably, sodium chloride, sodium bromide, sodium iodide, lithiumchloride, lithium bromide, lithium iodide, potassium chloride, potassiumbromide, potassium iodide and mixtures thereof are used in the presentinvention.

The relative amounts of organic complexing ligand and alkaline metalsalt used in the present invention can vary. A skilled person cancontrol catalyst activity, polyol viscosity and the like by varyingthese amounts. Preferably, DMC catalysts produced by the process of thepresent invention are composed of at least one alkaline metal salt whichis present in an amount within the range of from about 0.1 to about 10wt. %, more preferably, from about 0.4 to about 6 wt. %, mostpreferably, from about 1 to about 3 wt. %, based on the total weight ofthe DMC catalyst.

DMC catalysts of the present invention can optionally include at leastone functionalized polymer. “Functionalized polymer” is defined as apolymer or its salt which contains one or more functional groupsincluding oxygen, nitrogen, sulfur, phosphorus or halogen. Examples offunctionalized polymers useful in the present invention include, forexample: polyethers; polyesters; polycarbonates; polyalkylene glycolsorbitan esters; polyalkylene glycol glycidyl ethers; polyacrylamides;poly(acrylamide-co-acrylic acids), polyacrylic acids, poly(acrylicacid-co-maleic acids), poly(N-vinylpyrrolidone-co-acrylic acids),poly(acrylic acid-co-styrenes) and their salts; maleic acids, styrenesand maleic anhydride copolymers and their salts; block copolymers whichare composed of branched chain ethoxylated alcohols; alkoxylatedalcohols such as NEODOL which is sold commercially by Shell ChemicalCompany; polyether; polyacrylonitriles; polyalkyl acrylates; polyalkylmethacrylates; polyvinyl methyl ethers; polyvinyl ethyl ethers;polyvinyl acetates; polyvinyl alcohols; poly-N-vinylpyrrolidones;polyvinyl methyl ketones; poly(4-vinylphenols); oxazoline polymers;polyalkyleneimines; hydroxyethylcelluloses; polyacetals; glycidylethers; glycosides; carboxylic acid esters of polyhydric alcohols; bileacids and their salts, esters or amides; cyclodextrins; phosphoruscompounds; unsaturated carboxylic acid esters; and ionic surface- orinterface-active compounds. Polyether polyols are preferably used.

When used, functionalized polymers are present in the DMC catalyst in anamount within the range of from about 2 to about 80 wt. %, preferably,within the range of from about 5 to about 70 wt. %, more preferably,within the range of from about 10 to about 60 wt. %, based on the totalweight of DMC catalyst.

The combination of metal salt, metal cyanide salt, organic complexingligand, alkali metal salt and, optionally, functionalized polymer, canbe accomplished by any of the methods known in the art. Such methodsinclude, for example, precipitation, dispersion and incipient wetness.Preferably, the process of the present invention involves using aprecipitation method in which an aqueous solution of at least one metalsalt employed in a stoichiometric excess, i.e., at least 50 mol. %,based on the molar amount of metal cyanide salt, is mixed with anaqueous solution of at least one metal cyanide salt, at least one alkalimetal salt and, optionally, at least one functionalized polymer, in thepresence of at least one organic complexing ligand.

The alkali metal salt can be added to either the aqueous solution ofmetal salt or to the aqueous solution of metal cyanide salt or to bothsolutions or to the mixture after the two solutions are combined.Preferably, the alkaline metal salt is added to the aqueous solution ofmetal salt. The organic complexing ligand can be added to either theaqueous solution of metal salt or to the aqueous solution of metalcyanide salt or to both solutions or to the mixture after the twosolutions are combined or it can be added after formation of theprecipitate. The functionalized polymer can be added to either theaqueous solution of metal salt or to the aqueous solution of metalcyanide salt or to both solutions or to the mixture after the twosolutions are combined or it can be added after formation of theprecipitate.

The reactants are mixed using any of the mixing methods known in theart, such as, for example, by simple mixing, high-shear mixing orhomogenization. Preferably, the reactants are combined with simplemixing at a temperature within the range of from about room temperatureto about 80° C. A precipitate forms when the reactants are mixed.

The resulting precipitate is isolated from suspension by knowntechniques such as, for example, by centrifugation, filtration,filtration under pressure, decanting, phase separation or aqueousseparation.

The isolated precipitate is preferably washed at least once with waterand/or with a mixture which is preferably composed of water and at leastone organic complexing ligand. More preferably, this mixture is composedof water, at least one organic complexing ligand and at least onealkaline metal salt. Most preferably, this mixture is composed of water,at least one organic complexing ligand, at least one alkaline metal saltand at least one functionalized polymer.

Preferably, the isolated precipitate is filtered from the wash mixtureby known techniques such as, for example, centrifugation, filtration,filtration under pressure, decanting, phase separation or aqueousseparation. The filtered precipitate is preferably washed at least oncewith a mixture which is preferably composed of at least one organiccomplexing ligand. More preferably, this mixture is composed of water,at least one organic complexing ligand and at least one alkaline metalsalt. Most preferably, this mixture is composed of water, at least oneorganic complexing ligand, at least one alkaline metal salt and at leastone functionalized polymer.

The present invention is also directed to a process for preparing apolyol in the presence of a DMC catalyst of or prepared according to thepresent invention.

Any starter compound which has active hydrogen atoms can be used in thepresent invention. Starter compounds which are useful in the presentinvention include compounds having number average molecular weightsbetween 18 to 2,000, preferably, between 32 to 2,000, and which havefrom 1 to 8 hydroxyl groups. Examples of starter compounds which can beused in the present invention include, for example, polyoxypropylenepolyols, polyoxyethylene polyols, polytetatramethylene ether glycols,glycerol, propoxylated glycerols, tripropylene glycol, alkoxylatedallylic alcohols, bisphenol A, pentaerythritol, sorbitol, sucrose,degraded starch, water and mixtures thereof.

Monomers or polymers which will copolymerize with an oxide in thepresence of a DMC catalyst can be included in the process of the presentinvention to produce various types of polyols. The build-up of thepolymer chains by alkoxylation can be accomplished randomly orblockwise. Additionally, any copolymer known in the art made using aconventional DMC catalyst can be made with the DMC catalyst preparedaccording to the process of the present invention.

Any alkylene oxide can be used in the present invention. Alkylene oxidespreferably used in the present invention include, for example, ethyleneoxide, propylene oxide, butylene oxide and mixtures thereof.

Oxyalkylation of the starter compound can be accomplished by any of themethods known in the art, such as, for example, in a batch, semi-batchor continuous process. Oxyalkylation is carried out at a temperature inthe range of from about 20 and 200° C., preferably, from about 40 and180° C., more preferably, from about 50 and 150° C. and under an overallpressure of from about 0.0001 to about 20 bar. The amount of DMCcatalyst used in the oxyalkylation reaction is chosen such thatsufficient control of the reaction is possible under the given reactionconditions. The DMC catalyst concentration of an oxyalkylation reactionis typically in the range of from about 0.0005 wt. % to about 1 wt. %,preferably, from about 0 0.001 wt. % to about 0.1 wt. %, morepreferably, from about 0.001 to about 0.0025 wt. %, based on the totalweight of polyol to be prepared.

The number average molecular weight of the polyol prepared by theprocess of the present invention is in the range of from about 500 toabout 100,000 g/mol, preferably, from about 1,000 to about 12,000 g/mol,more preferably, from about 2,000 to about 8,000 g/mol. Polyols preparedby the process of the present invention have average hydroxylfunctionalities of from about 1 to 8, preferably, from about 2 to 6, andmore preferably, from about 2 to 3.

DMC catalysts of the present invention can be used to produce polyolswhich have reduced levels of high molecular weight tail (greater than400 K). The amount of high molecular weight tail is quantified by anysuitable method. A particularly convenient way to measure the amount ofhigh molecular weight tail is by gel permeation chromatography (GPC). Asuitable technique for measuring high molecular weight tail is describedbelow as well as in, for example, U.S. Pat. No. 6,013,596.

The following examples merely illustrate the invention. Those skilled inthe art will recognize many variations that are within the spirit of theinvention and scope of the claims.

EXAMPLES

A DMC catalyst which was prepared according to any one of Examples 1-16set forth below was used to prepare a 6000 MW polyoxypropylene triol byadding propylene oxide over 4 hours to an activated mixture composed ofthe DMC and a propoxylated glycerin starter (hydroxyl number=240 mgKOH/g). Catalyst levels of 30 ppm were used. The hydroxyl number,viscosity and unsaturation of each product were measured by standardmethods. A gel permeation chromatography (GPC) technique as described inU.S. Pat. No. 6,013,596, the teachings of which are incorporated hereinby reference, was used to measure the amount of polyol component havinga number average molecular weight (Mn) from 40,000 to >400,000. Theamount present (in ppm) is recorded and the percent of high molecularweight (HMW) tail reduction of the catalyst for each range of molecularweight is calculated using the following formula (hereinafter referredto as “Formula I”):

% Reduction*=(HMW tail of comparative example−HMW tail of polyolprepared with a DMC catalyst of the present invention)×100%/HMW tail ofcomparative control

* no reduction of HMW tail is obtained if the % reduction is less thanzero.

Example 1

Preparation of a DMC Catalyst Using Sodium Chloride and aPolyoxypropylene Diol:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor (Solution 1). Potassium hexacyanocobaltate(7.5 g.) and sodium chloride (4 g.) were dissolved in a 500-ml beakerwith deionized water (100 g) and tert-butyl alcohol (15.5 g.) (Solution2). Solution 3 was prepared by dissolving a 1000 mol. wt.polyoxypropylene diol (8 g.) in deionized water (50 g.) and tert-butylalcohol (2 g.). Solution 2 was added to Solution 1 over 45 min. whilemixing at 1,500 rpm. The reaction temperature was kept at 50° C. duringthe course of the reaction by using an internal coil for heating orcooling. Following the addition, mixing continued at 1,500 rpm for 20min. The mixing was stopped. Solution 3 was then added, followed by slowstirring for 3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g) and sodium chloride (2 g) andmixed at 1,500 rpm for 20 min. The mixing was stopped. 1000 mol. wt.polyoxypropylene diol (2 g.) was added and the mixture was stirredslowly for 3 min. The catalyst was filtered as described above. The cakewas re-slurried in tert-butyl alcohol (144 g.) and mixed as describedabove. 1000 mol. wt. polyoxypropylene diol (1 g.) was added and theproduct was filtered as described above. The resulting catalyst residuewas dried in a vacuum oven at 60° C., 30 in. (Hg) to constant weight.

Elemental analysis: Cobalt=9 wt. %; Zinc=21.7 wt. %; Sodium=0.75 wt. %;Cl=6.1 wt. %

Example 2

Preparation of a DMC Catalyst Using Lithium Chloride and aPolyoxypropylene Diol:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor. Lithium chloride (0.3 g.) was added to thissolution (Solution 1). Potassium hexacyanocobaltate (7.5 g.) wasdissolved in a 500-ml beaker with deionized water (100 g.) andtert-butyl alcohol (15.5 g.) (Solution 2). Solution 3 was prepared bydissolving a 1000 mol. wt. polyoxypropylene diol (8 g.) in deionizedwater (50 g.) and tert-butyl alcohol (2 g.). Solution 2 was added toSolution 1 over 45 min. while mixing at 1,500 rpm. The reactiontemperature was kept at 50° C. during the course of the reaction byusing an internal coil for heating or cooling. Following the addition,mixing continued at 1,500 rpm for 20 min. The mixing was stopped.Solution 3 was added, followed by slow stirring for 3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g.) and lithium chloride (2 g.)and mixed at 1,500 rpm for 20 min. The mixing was stopped. 1000 mol. wt.polyoxypropylene diol (2 g.) was added and the mixture was stirredslowly for 3 min. The catalyst was filtered as described above. The cakewas re-slurried in tert-butyl alcohol (144 g.) and lithium chloride (0.5g.) and mixed as described above. 1000 mol. wt. polyoxypropylene diol (1g.) was added and the product was filtered as described above. Theresulting catalyst residue was dried in a vacuum oven at 60° C., 30 in.(Hg) to constant weight.

Elemental analysis: Cobalt=9.1 wt. %; Zinc=21.9 wt. %; Lithium=0.15 wt.%; Cl=4.8 wt. %

Example 3

Preparation of a DMC Catalyst Using Sodium Bromide and aPolyoxypropylene Diol:

The procedure of Example 2 was followed, except that NaBr was used inlieu of LiCl.

Elemental analysis: Cobalt=8.1 wt. %; Zinc=21.9 wt. %; Sodium=0.48 wt.%; Cl=3.8 wt. %; Br=3.8 wt. %

Example 4

Preparation of a DMC Catalyst Using Lithium Bromide and aPolyoxypropylene Diol:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor. Lithium bromide (4 g.) was added to thissolution (Solution 1). Potassium hexacyanocobaltate (7.5 g.) wasdissolved in a 500-ml beaker with deionized water (100 g.) andtert-butyl alcohol (15.5 g.) (Solution 2). Solution 3 was prepared bydissolving a 1000 mol. wt. polyoxypropylene diol (8 g.) in deionizedwater (50 g.) and tert-butyl alcohol (2 g.). Solution 2 was added toSolution 1 over 45 min. while mixing at 1,500 rpm. The reactiontemperature was kept at 50° C. during the course of the reaction byusing an internal coil for heating or cooling. Following the addition,mixing continued at 1,500 rpm for 20 min. The mixing was stopped.Solution 3 was added, followed by slow stirring for 3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.) and deionized water (55 g) and mixed at 1,500 rpm for20 min. The mixing was stopped. 1000 mol. wt. polyoxypropylene diol (2g.) was added and the mixture was stirred slowly for 3 min. The catalystwas filtered as described above. The cake was re-slurried in tert-butylalcohol (144 g.) and mixed as described above. 1000 mol. wt.polyoxypropylene diol (1 g.) was added and the product was filtered asdescribed above. The resulting catalyst residue was dried in a vacuumoven at 60° C., 30 in. (Hg) to constant weight.

Elemental Analysis Zn=23.4 wt. %; Co=10.8 wt. %; Li=<0.02 wt. %; Br: 0.4wt. %; Cl=3.6 wt. %

Example 5

Preparation of a DMC Catalyst Using Sodium Chloride and a Diol ofPropylene Oxide and Ethylene Oxide Copolymer:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor. Sodium chloride (0.3 g.) was added to thissolution (Solution 1). Potassium hexacyanocobaltate (7.5 g.) wasdissolved in a 500-ml beaker with deionized water (100 g.) andtert-butyl alcohol (15.5 g.) (Solution 2). Solution 3 was prepared bydissolving 8 g. of a 4000 mol. wt. diol of propylene oxide and ethyleneoxide copolymer (80:20 wt. ratio) in deionized water (50 g.) andtert-butyl alcohol (2 g.). Solution 2 was added to Solution 1 over 45min. while mixing at 900 rpm. The reaction temperature was kept at 50°C. during the course of the reaction by using an internal coil forheating or cooling. Following the addition, mixing continued at 900 rpmfor 20 min. The mixing was stopped. Solution 3 was added, followed byslow stirring for 3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g.) and sodium chloride (2 g.) andmixed at 900 rpm for 20 min. The mixing was stopped. 4000 mol. wt. diol(2 g.) was added and the mixture was stirred slowly for 3 min. Thecatalyst was filtered as described above. The cake was re-slurried intert-butyl alcohol (144 g.) and sodium chloride (1 g.) and mixed asdescribed above. 4000 mol. wt. diol (1 g.) was added and the product wasfiltered as described above. The resulting catalyst residue was dried ina vacuum oven at 60° C., 30 in. (Hg) to constant weight.

Elemental analysis: Cobalt=8.8 wt. %; Zinc=20.3 wt. %; Sodium=2.4 wt. %

Example 6

Preparation of a DMC Catalyst Using Potassium Chloride and aPolyoxypropylene Diol:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor (Solution 1). Potassium hexacyanocobaltate(7.5 g.) and potassium chloride (4.0 g) were dissolved in a 500-mlbeaker with deionized water (100 g.) and tert-butyl alcohol (15.5 g.)(Solution 2). Solution 3 was prepared by dissolving 8 g. of a 1000 mol.wt. polyoxypropylene diol (8 g.) in deionized water (50 g.) andtert-butyl alcohol (2 g.). Solution 2 was added to Solution 1 over 45min. while mixing at 500 rpm. The reaction temperature was kept at 50°C. during the course of the reaction by using an internal coil forheating or cooling. Following the addition, mixing continued at.500 rpmfor 20 min. The mixing was stopped. Solution 3 was added, followed byslow stirring for 3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g.) and mixed at 500 rpm for 20min. The mixing was stopped. 1000 mol. wt. diol (2 g.) and potassiumchloride (2 g) were added and the mixture was stirred slowly for 3 min.The catalyst was isolated as described above. The cake was re-slurriedin tert-butyl alcohol (125 g) and deionized water (30 g) and was mixedat 500 rpm for 20 min. The mixing was stopped. 1000 mol. wt. diol (2 g)and potassium chloride (2 g) were added and the mixture was stirredslowly for 3 min. The catalyst was filtered as described above. The cakewas re-slurried in tert-butyl alcohol (144 g.) and mixed as describedabove. 1000 mol. wt. diol (1 g.) was added and the product was filteredas described above. The resulting catalyst residue was dried in a vacuumoven at 60° C., 30 in. (Hg) to constant weight.

Elemental analysis: Co=9.4 wt. %; Zn=20 wt. %; K=6.1 wt. %.

Example 7

Preparation of a DMC Catalyst Using Potassium Chloride, aPolyoxypropylene Diol and a Poly(Styrene-alt-maleic Acid, Sodium Salt)(30 wt % in Water):

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor (Solution 1). Potassium hexacyanocobaltate(7.5 g.) and potassium chloride (4.0 g.) were dissolved in a 500-mlbeaker with deionized water (100 g.) and tert-butyl alcohol (15.5 g.)(Solution 2). Solution 3 was prepared by dissolving 8 g. of a 1000 mol.wt. polyoxypropylene diol in deionized water (50 g.) and tert-butylalcohol (2 g.). Solution 2 was added to Solution 1 over 45 min. whilemixing at 500 rpm. The reaction temperature was kept at 500C during thecourse of the reaction by using an internal coil for heating or cooling.Following the addition, mixing continued at 500 rpm for 20 min. Themixing was stopped. Solution 3 was added, followed by slow stirring for3 min.

The reaction mixture was filtered at 40 psig through a 0.45μ nylonmembrane. The catalyst cake was re-slurried in a mixture of potassiumchloride (2 g.), tert-butyl alcohol (100 g.), poly(styrene-alt-maleicacid, sodium salt) solution (7 g.) and deionized water (55 g.) and mixedat 800 rpm for 20 min. The mixing was stopped. 1000 mol. wt. diol (2 g.)was added and the mixture was stirred slowly for 3 min. The catalyst wasisolated as described above. The cake was re-slurried in tert-butylalcohol (144 g.) and mixed as described above. More 1000 mol. wt. diol(1 g.) was added and the product was filtered as described above. Theresulting catalyst residue was dried in a vacuum oven at 60°C., 30 in.(Hg) to constant weight.

Elemental analysis: Co=10.1 wt. %; Zn=22.4 wt. %; K=1.86 wt. %.

Example 8

Preparation of a DMC Catalyst Using Potassium Chloride, aPolyoxypropylene Diol and a Poly(Methacrylic Acid, Sodium Salt) (30 wt %Solution in Water):

The procedure of Example 7 was followed, except that poly(methacrylicacid, sodium salt) (30 wt % solution in water) was used in lieu ofpoly(styrene-alt-maleic acid, sodium salt) (30 wt % solution in water).

Elemental analysis: Co=8 wt. %; Zn=21.6 wt. %; K=4.3 wt. %.

Example 9

Preparation of a DMC Catalyst Using Sodium Chloride but NoFunctionalized Polymer:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor. Sodium chloride (0.3 g.) was added to thissolution (Solution 1). Potassium hexacyanocobaltate (7.5 g.) wasdissolved in a 500-ml beaker with deionized water (100 g.) andtert-butyl alcohol (15.5 g.) (Solution 2). Solution 2 was added toSolution 1 over 45 min. while mixing at 800 rpm. The reactiontemperature was kept at 50° C. during the course of the reaction byusing an internal coil for heating or cooling. Following the addition,mixing continued at 800 rpm for 20 min. The mixing was stopped.

The reaction mixture was filtered at 40 psig through a 0.65μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g.) and sodium chloride (2 g.) andmixed at 800 rpm for 20 min. The mixing was stopped. The catalyst wasisolated as described above. The cake was re-slurried in tert-butylalcohol (144 g.) and sodium chloride and mixed as described above. Theproduct was isolated as described above. The resulting catalyst residuewas dried in a vacuum oven at 60° C., 30 in. (Hg) to constant weight.

Elemental Analysis: Zn=25.9 wt. %; Co=12 wt. %; Na=1.29 wt. %.

Example 10 (Comparative)

Preparation of a DMC Catalyst Using a Functionalized Polymer but NoSalt:

The procedure of Example 1 was followed, except that no NaCl was added.

Elemental analysis: Cobalt=9 wt. %; Zinc=21.6 wt. %; Cl=4.1 wt. %

Examples 11, 12 and 13 (all Comparative)

Preparation of a DMC Catalyst Using a Functionalized Polymer but NoSalt:

For Comparative Examples 11, 12 and 13, DMC catalysts were preparedaccording to the procedure of Example 1, except that no NaCl was added.

Elemental analysis: Cobalt=10.3 wt. %; Zinc=23.2 wt. %; Cl=4.0 wt. %;K=0.21 wt. %

Example 14 (Comparative)

Preparation of a DMC Catalyst Using No Functionalized Polymer and NoSalt:

An aqueous zinc chloride solution (120 g. of 62.5 wt. % ZnCl₂) wasdiluted with deionized water (230 g.) and tert-butyl alcohol (38 g.) ina one-liter stirred reactor (Solution 1). Potassium hexacyanocobaltate(7.5 g.) was dissolved in a 500-ml beaker with deionized water (100 g.)and tert-butyl alcohol (15.5 g.) (Solution 2). Solution 2 was added toSolution I over 45 min. while mixing at 800 rpm. The reactiontemperature was kept at 50° C. during the course of the reaction byusing an internal coil for heating or cooling. Following the addition,mixing continued at 800 rpm for 20 min. The mixing was stopped.

The reaction mixture was filtered at 40 psig through a 0.65μ nylonmembrane. The catalyst cake was re-slurried in a mixture of tert-butylalcohol (100 g.), deionized water (55 g.) and mixed at 800 rpm for 20min. The mixing was stopped. The catalyst was isolated as describedabove. The cake was re-slurried in tert-butyl alcohol (144 g.) and mixedas described above. The product was isolated as described above.

The resulting catalyst residue was dried in a vacuum oven at 60° C., 30in. (Hg) to constant weight.

Elemental Analysis: Co=12.4 wt. %; Zn=26.8 wt. %.

Example 15

Preparation of a DMC Catalyst Using Sodium Chloride and a BlockCopolymer of NEODOL-(EO)_(m)-IBO:

The procedure of Example 5 was followed except that a block copolymer ofNEODOL-(EO)_(m)-IBO was used in lieu of the 1000 mol. wt. diol. Theblock copolymer was prepared using NEODOL (which is availablecommercially from Shell Chemical Company) as a starter and a DMCcatalyst prepared essentially by the method of U.S. Pat. No. 5,482,908(the teachings of which are incorporated herein by reference) to producea polyoxyethylene having a molecular weight of about 1000. Thisdi-blockcopolymer was end-capped by 1-2 units of isobutylene oxide.

Example 16 (Comparative)

Preparation of a DMC Catalyst Using Zinc Hexacyanocobaltate/t-butylAlcohol and a Polyoxypropylene Diol:

The procedure of Example 1 was followed, except that no NaCl was added.

Elemental analysis: Cobalt=9 wt. %; Zinc=21.6 wt. %

As illustrated in Table 1, DMC catalysts prepared according to theprocess of the present invention, such as those prepared in Examples1-5, (prepared with an alkaline metal salt and a functionalizedpolymer), can be used to produce polyols which have an acceptable amountof high molecular weight tail.

TABLE 1 Catalyst of Ex # 10* 1 2 3 4 5 Additive None NaCl LiCl NaBr LiBrNaCl Na or Li in Catalyst None 0.75 0.15 0.48 <0.02 2.4 [wt. %] (Na)(Li) (Na) (Li) (Na) Polymerization Rate 21.7 16.4 19.1 23.7 20.7 16.1[Kg.PO/g.Co/min.] 6000 MW Triol: OH# [mg KOH/g] 29.7 28.4 30.6 29.8 30.329.7 Viscosity [cps] 1105 1120 1087 1156 1054 1130 Unsaturation [meq/g]0.005 0.0055 0.0048 0.0056 0.0046 0.0064 HMW Tail: (MW) (ppm) (ppm)(ppm) (ppm) (ppm) (ppm) 40-60 K 855 616 609 558 724 672 60-80 K 465 316330 250 409 344  80-100 K 287 190 206 118 248 203 100-200 K 337 235 249229 318 261 200-400 K 120 94 99 99 119 91 >400 K 40 30 37 40 48 21 6000MW Triol prepared at 130° C., 4 hour-PO addition with 30 ppm of catalystbased on the amount of polyol made. HMW tail based on six portion-cutGPC. *Comparative

As illustrated in Table 2, DMC catalysts prepared according to theprocess of the present invention, such as those prepared in Examples1-5, (prepared with an alkaline metal salt and a functionalizedpolymer), can be used to produce polyols which have a reduced amount ofhigh molecular weight tail compared to a polyol produced in the presenceof a DMC catalyst which is prepared with a functionalized polymer but noalkaline metal salt. Such as the one prepared in Comparative Example 10.The percent reduction of high molecular weight tail was determined byFormula 1.

TABLE 2 Catalyst of Ex # 1 2 3 4 5 Additive NaCl LiCl NaBr LiBr NaCl Naor Li in Catalyst [wt. %] 0.75 0.15 0.48 <0.02 2.4 6000 MW Triol: (Na)(Li) (Na) (Li) (Na) OH# [mg KOH/g] 28.4 30.6 29.8 30.3 29.7 Viscosity[cps] 1120 1087 1156 1054 1130 Unsaturation [meq/g] 0.0055 0.0048 0.00560.0046 0.0064 HMW Tail: (MW) % Reduction % Reduction % Reduction %Reduction % Reduction 40-60 K 28 29 35 15 21 60-80 K 32 29 46 12 26 80-100 K 34 28 59 14 29 100-200 K 30 26 32 6 23 200-400 K 22 18 18 124 >400 K 25 8 0 −20 48 6000 MW Triol prepared at 130° C., 4 hour-POaddition with 30 ppm of catalyst based on the amount of polyol made HMWtail based on six portion-cut GPC.

As illustrated in Table 3, DMC catalysts prepared according to theprocess of the present invention, such as the one prepared in Example 6(prepared with an alkaline metal salt and a functionalized polymer), canbe used to produce a polyol having a reduced amount of high molecularweight tail compared to a polyol produced in the presence of a DMCcatalyst which is prepared with a functionalized polymer but no alkalinemetal salt, such as the one prepared in Comparative Example 11. Thepercent reduction of high molecular weight tail was determined byFormula I.

TABLE 3 Catalyst of Ex # 11* 6 6 Additive None KCl KCl Potassium incatalyst 0.21 6.1 6.1 [wt. %] 6000 MW Triol: OH# [mg KOH/g] 29.5 29.929.9 Viscosity [cps] 1109 1131 1131 Unsaturation [meq/g] 0.006 0.00760.0076 HMW Tail: (MW) (ppm) (ppm) (% Reduction)   40-50.4 K 1169 608 4850.4-63.4 K 920 448 51 63.4-79.8 K 719 366 49  79.8-100.5 K 564 332 41100.5-126.5 K 430 247 43 126.5-159.2 K 245 126 49 159.2-200.5 K 164 8250 200.5-252.4 K 108 50 54 252.4-317.7 K 69 29 58 317.7-400 K   48 1667 >400 K 33 0 100 6000 MW Triol prepared at 130° C., 4-hour-PO additionwith 30 ppm of catalyst based on the amount of polyol HMW tail based onten portion-cut GPC. *Comparative

As illustrated in Table 4, DMC catalysts prepared according to theprocess of the present invention, such as the one prepared in Example 7(prepared with an alkaline metal salt and a functionalized polymer), canbe used to produce a polyol having a reduced amount of high molecularweight tail compared to a polyol produced in the presence of a DMCcatalyst which is prepared with a functionalized polymer but no alkalinemetal salt, such as the one prepared in Comparative Example 12. Thepercent reduction of high molecular weight tail was determined byFormula I.

TABLE 4 Catalyst of Ex # 12* 7 7 Additive None KCl KCl Potassium incatalyst 0.21 1.86 1.86 [wt. %] 6000 MW Triol: OH# [mg KOH/g] 29.2 29.529.5 viscosity [cps] 1113 1093 1093 Unsaturation [meq/g] 0.0055 0.00610.0061 HMW Tail: (MW) (ppm) (ppm) (% Reduction)   40-50.4 K 1115 649 4250.4-63.4 K 869 479 45 63.4-79.8 K 760 421 45  79.8-100.5 K 603 356 41100.5-126.5 K 457 267 42 126.5-159.2 K 286 156 46 159.2-200.5 K 203 11245 200.5-252.4 K 131 74 44 252.4-317.7 K 93 52 44 317.7-400 K   58 3343 >400 K 41 23 44 6000 MW Triol prepared at 130° C., 4 hour-PO additionwith 30 ppm of catalyst base on the am ount of polyol made. HMW tailbased on ten portion-cut GPC. *Comparative

As illustrated in Table 5, DMC catalysts prepared according to theprocess of the present invention, such as the one prepared in Example 8(prepared with an alkaline metal salt and a functionalized polymer), canbe used to produce a polyol having a reduced amount of high molecularweight tail compared to a polyol produced in the presence of a DMCcatalyst which is prepared with a functionalized polymer but no alkalinemetal salt, such as the one prepared in Comparative Example 13. Thepercent reduction of high molecular weight tail was determined byFormula I.

TABLE 5 Catalyst of Ex # 13* 8 8 Additive None KCl KCl Potassium incatalyst 0.21 4.3 4.3 [wt. %] 6000 MW Triol: OH# [mg KOH/g] 29.8 29.629.6 viscosity [cps] 1112 1108 1108 Unsaturation [meq/g] 0.0055 0.00610.0061 HMW Tail: (MW) % Reduction   40-50.4 K 1290 685 47 50.4-63.4 K1031 476 54 63.4-79.8 K 8i5 403 51  79.8-100.5 K 641 350 45 100.5-126.5K 473 277 41 126.5-159.2 K 266 159 40 159.2-200.5 K 177 94 47200.5-252.4 K 109 55 50 317.7-400 K   47 0 100 252.4-317.7 K 75 1975 >400 K 22 0 100 6000 MW Triol prepared at 130° C. 4 hour-PO additionwith 30 ppm of catalyst based on the amount of polyol made. HMW tailbased on ten portion-cut GPC. *Comparative

As illustrated in Table 6, DMC catalysts prepared according to theprocess of the present invention, such as the one prepared in Example 9(prepared with an alkaline metal salt but no functionalized polymer),can be used to produce a polyol having a reduced amount of highmolecular weight tail compared to a polyol produced in the presence of aDMC catalyst which is prepared without a functionalized polyol andalkaline metal salt, such as the one prepared in Comparative Example 14.The percent reduction of high molecular weight tail was determined byFormula I.

TABLE 6 Catalyst of Ex # 14* 9 9 Additive None NaCl NaCl Sodium incatalyst None 1.29 1.29 [wt. %] Polymerization Rate [Kg.PO/g.Co/min.]14.3 12.9 12.9 6000 MW Triol: OH# [mg KOH/g] 29.4 29.2 29.2 Viscosity[cps] 1169 1198 1198 Unsaturation [meq/g] 0.0043 0.0049 0.0049 HMW Tail:(MW) (ppm) (ppm) (% Reduction) 40-60 K 1680 1412 16 60-80 K 906 745 18 80-100 K 537 436 19 100-200 K 591 476 19 200-400 K 196 175 11 >400 K 6364 −2 6000 MW Triol prepared at 130° C., 4 hour-PO addition with 30 ppmof catalyst based on the amount of polyol made. HMW tail based on sixportion-cut GPC. *Comparative

As illustrated in Table 7, DMC catalysts prepared according to theprocess of the present invention, such as the one prepared in Example 15(prepared with an alkaline metal salt and a functionalized polymer), canbe used to produce a polyol having a reduced amount of high molecularweight tail compared to a polyol produced in the presence of a DMCcatalyst which is prepared with a functionalized polymer but no alkalinemetal salt, such as the one prepared in Comparative Example 16. Thepercent reduction of high molecular weight tail was determined byFormula I.

TABLE 7 Catalyst of Ex 16 (Compara- tive) 15 15 Additive None NaCl NaClNa in Catalyst None 0.88 0.88 [wt. %] 6000 MW OH# [mg OH/g] 29.8 30 30Viscosity [cps] 1095 1137 1137 Unsaturation [meq/g] 0.0052 0.0051 0.0051HMW Tail: (MW) (ppm) (ppm) % Reduction 40-60 K 1064 574 46 60-80 K 581281 52  80-100 K 352 154 56 100-200 K 382 199 48 200-400 K 123 8035 >400 K 41 23 44 6000 MW Triol prepared at 130° C., 4-hour PO additionwith 30 ppm catalyst based on the amount of poiyoi made. HMW tail basedon six portion cut GPC

What is claimed is:
 1. A double-metal cyanide catalyst prepared bycombining at least one metal salt, at least one metal cyanide salt, atleast one organic complexing ligand, at least one alkali metal salt, andoptionally, at least one functionalized polymer, under conditionssufficient to form a catalyst; and adding the at least one alkali metalsalt to the catalyst so formed in an amount such that the catalystincludes the at least one alkali metal salt in an amount of from about0.4 to about 6 wt. % based on the total weight of the catalyst.
 2. Thedouble metal cyanide catalyst of claim 1, wherein the at least one metalsalt is selected from the group consisting of zinc chloride, zincbromide, zinc acetate, zinc acetylacetonate, zinc benzoate, zincnitrate, zinc propionate, zinc formate, iron(II) sulfate, iron(II)bromide, cobalt(II) chloride, cobalt(II) thiocyanate, nickel(II)formate, nickel(II) nitrate and mixtures thereof.
 3. The double metalcyanide catalyst of claim 1, wherein the at least one metal cyanide saltis selected from the group consisting of potassium hexacyanocobaltate(III), potassium hexacyanoferrate(II), potassium hexacyanoferrate(III),lithium hexacyanoiridate(III), lithium hexacyanocobaltate(III), sodiumhexacyanocobaltate(III) and cesium hexacyanocobaltate(III).
 4. Thedouble metal cyanide catalyst of claim 1, wherein the at least oneorganic complexing ligand is selected from the group consisting ofethanol, isopropanol, n-butanol, iso-butanol, sec-butanol and tert-butylalcohol.
 5. The double metal cyanide catalyst of claim 1, wherein the atleast one alkali metal salt is selected from the group consisting ofpotassium chloride, sodium chloride, sodium bromide, lithium chlorideand lithium bromide.
 6. The double metal cyanide catalyst of claim 1,wherein the at least one functionalized polymer is present In an amountin the range of from about 2 to about 98 wt. %, based on the totalweight of the double-metal cyanide catalyst.
 7. The double metal cyanidecatalyst of claim 1, wherein the at least one functionalized polymer isa polyether: polyester; polycarbonate; polyalkylene glycol sorbitanester; polyalkylene glycol glycidyl ether; polyacrylamide;poly(acrylamide-co-acrylic acid), polyacrylic acid, poly(acrylicacid-co-maleic acid), poly(N-vinylpyrrolidone-co-acrylic acid),poly(acrylic acid-co-styrene) or their salts; maleic acid, styrene ormaleic anhydride copolymers or their salts; polyacrylonitriles;polyalkyl acrylate; polyalkyl methacrylate; polyvinyl methyl ether;polyvinyl ethyl ether; polyvinyl acetate; polyvinyl alcohol;poly-N-vinylpyrrolidone; polyvinyl methyl ketone; poly(4-vinylphenol)oxazoline polymer; polyalkyleneimine; hydroxyethylcellulose; polyacetal;glycidyl ether; glycoside; carboxylic acid ester of polyhydric alcohol;bile acid or its salt, ester or amide; cyclodextrin; phosphoruscompound; unsaturated carboxylic acid ester; or an ionic surface orinterface-active compound.
 8. A process for preparing a double-metalcyanide catalyst comprising: combining at least one metal salt; at leastone metal cyanide salt; at least one organic complexing ligand; at leastone alkali metal salt; and optionally, at least one functionalizedpolymer; under conditions sufficient to form a catalyst; and adding atleast one alkali metal salt to the catalyst so formed in an amount suchthat the catalyst includes the at least one alkali metal salt in anamount of from about 0.4 to about 6 wt. % based on the total weight ofthe catalyst.
 9. The process of claim 8, wherein the at least one metalsalt is selected from the group consisting of zinc chloride, zincbromide, zinc acetate, zinc acetylacetonate, zinc benzoate, zincnitrate, zinc propionate, zinc formate, iron(II) sulfate, iron(II)bromide, cobalt(II) chloride, cobalt(II) thiocyanate, nickel(II)formate, nickel(II) nitrate and mixtures thereof.
 10. The process ofclaim 8, wherein the at least one metal cyanide salt is selected fromthe group consisting of potassium hexacyanocobaltate (III), potassiumhexacyanoferrate(II), potassium hexacyanoferrate(III), lithiumhexacyanoiridate(III), lithium hexacyanocobaltate(III), sodiumhexacyanocobaltate(III) and cesium hexacyanocobaltate(III).
 11. Theprocess of claim 8, wherein the at least one organ complexing ligand isselected from the group consisting of ethanol, isopropanol, n-butanol,iso-butanol, sec-butanol and tert-butyl alcohol.
 12. The process ofclaim 8, wherein the at least one alkaline metal salt is selected fromthe group consisting of potassium chloride, sodium chloride, sodiumbromide, lithium chloride and lithium bromide.
 13. The process of claim8, wherein the at least one functionalized polymer is present in anamount in the range of from about 2 to about 98 wt. %, based on thetotal weight of the double-metal cyanide catalyst.
 14. The process ofclaim 8, wherein the at least one functionalized polymer is a polyether;polyester; polycarbonate; polyalkylene glycol sorbitan ester;polyalkylene glycol glycidyl ether; polyacrylamide;poly(acrylamide-co-acrylic acid), polyacrylic acid, poly(acrylicacid-co-maleic acid), poly(N-vinylpyrrolidone-co-acrylic acid),poly(acrylic acid-co-styrene) or their salts; maleic acid, styrene ormaleic anhydride copolymers or their salts; polyacrylonitriles;polyalkyl acrylate; polyalkyl methacrylate; polyvinyl methyl ether;polyvinyl ethyl ether; polyvinyl acetate; polyvinyl alcohol;poly-N-vinylpyrrolidone; polyvinyl methyl ketone; poly(4-vinylphenol);oxazoline polymer; polyalkyleneimine; hydroxyethylcellulose; polyacetal;glycidyl ether; glycoside; carboxylic acid ester of polyhydric alcohol;bile acid or Its salt, ester or amide; cyclodextrin; phosphoruscompound; unsaturated carboxylic acid ester; or an ionic surface- orinterface-active compound.